KALEA A2 – REPLACING THE DRIVE AND SAFETY NUTS

This procedure is to be undertaken with the platform positioned at the lowest floor level and with
the platform buffered.

Disassembly of the drive

To enable the drive screw to be removed from the drive nut requires the emergency drive be
dismantled from the top of the drive screw first. The emergency drive can be accessed by either of
the two means detailed below:

a) Depending on the lift travel, it may be possible to access the emergency drive via a ladder
placed on the platform

b) If it is possible to drive the lift, then the platform may be taken to the top floor and the
emergency drive unit accessed following removal of the cladding hood. The emergency
drive complete with mounting bracket should be removed (two socket screws secure
mounting bracket to cross beam) from the top nut and placed to one side. Then, one man
wearing industrial gloves holds the drive screw firmly to prevent it rotating, a second man
can then drive the platform down, say in 0.5 metre stages, whereby the first man
repositions his hold on the screw after each movement, until the lift arrives at the bottom
floor and is buffered.

Isolate and lock off the lift electrical supply.

Remove the platform access panel and then remove the fixing screws from one side hinge of the
controller cabinet (whichever side provides best access to the drive machine when the cabinet is
open). Ensure the cabinet opens sufficiently to provide adequate access to the drive machine (you
may need to free some of the electrical cables to allow the cabinet to open fully.

Remove all excess grease from the drive machine and surrounding components prior to beginning
dismantling of the drive unit.

Fig.1 Drive Machine

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The drive screw should be manually rotated by hand up and out of the safety and drive nuts.
Caution! When the screw exits the safety nut this will fall away. Ensure that a second man
is holding the safety nut as the screw draws out of it. Also, a spring resides in each of the
four coupling pin holes, ensure these do not become misplaced.

Do not remove the drive belt at this stage, as it will hold the drive nut stationary whilst the screw is
being rotated. Continue to rotate the screw until it exits the drive nut. The screw then needs to be
lifted up and onto the cross beam of the platform sling. Note: the screw is a heavy item and may
require two men to lift it.

As can be seen in Fig. 2. the drive nut and bearings are sandwiched between two mounting
plates. To access and remove these components requires the bottom plate to be removed.
However, the drive motor, which is a heavy lump, is suspended from the bottom plate. Although
not impossible to remove the bottom plate complete with motor (by means of a small lifting tackle
or jack), to aid alignment during reassembly it is probably best to remove the motor from the plate
and then remove the plate as shown in the illustrations.

Fig. 2. Drive Bearings are ‘Sandwiched’ between Top and Bottom Plates

Prior to removing the motor, slacken the four mounting screws (13 mm spanner) and release the
drive belt via the tensioning screw. Remove the belt from the motor pulley.

The motor pulley has to be removed from the motor shaft, as it will not pass through the slot in the
mounting plate. As can be seen in Fig.3. the pulley is fixed to the shaft via a ‘taper lock’ coupling.
The two socket screws should be removed from the coupling and then as shown in Fig. 4. one of
them screwed into the third hole to release the coupling.

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 Fig.3. Drive Pulley secured to Shaft via a Taper Lock Coupling and Two Socket Screws

Fig.4. Socket Screw Tightens into the Third Hole to Release the Taper Lock.

Prop the motor by suitable means (a car jack or timbers) to take the weight as it is released from
the bottom plate.

Slacken the cable clamp and pull through enough of the motor and brake cables to provide
adequate slack to allow the motor to be removed to the platform. With one man holding the motor
steady, remove the four motor mounting screws and then gently lower the motor onto the platform.

The bottom plate can now be removed. Slacken the four fixing screws (17 mm spanner).

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Remove the two fixing screws that also secure the nut wear switch bracket and place the bracket
on the floor.

With one man holding the plate the final two fixing screws are removed. The plate complete with
drive nut and bearing can then be gently lowered away. Be prepared for the weight of these
components. The components can then be separated from the plate.

Fig.5. Removal of Bottom Plate complete with Drive Nut and Bearings

Fig.6. Drive Nut and Bearings. Bottom Bearing located in Recess in Bottom Plate

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 Fig.7. Top Plate with Drive removed.

Reassembly

The procedure for reassembly is the reverse of that for disassembly but also including the
following:

Grease the inside of the new drive nut and safety nut prior to fitting.

Ensure the drive belt is fitted to the drive nut prior to fitting the bottom plate

Ensure the drive bearings sit correctly in the locating reassess in top and bottom plates and that
nut and bearings rotate freely after the plate fixings screws are secured.

While one man winds the screw down through the drive nut, the second man must hold the safety
nut coupled to the drive nut with a gap between the top of the safety nut steel tube and mounting
plate of 4 – 7 mm. Re: Fig 10.

The screw should be wound down through the drive nut until it can go no further without starting to
lift the platform. Check the gap above the safety nut tube is as stated above and if correct rotate
the drive nut until the horizontal hole in the safety nut tube is accessible (Fig. 10). With a 5mm
diameter drill bit extend the hole through the tube and into the drive nut approx 6 mm deep.
Caution! Do not drill any deeper as you may penetrate to the inside of the nut. The purpose
of this hole is to enable periodic checking of nut wear via the wear gauge (Re: Installation and
Inspection manuals).

Ensure the drive belt is correctly tensioned.

Set the nut wear switch roller to have a clearance of 0.5mm with nut disc.

Ensure the drive screw is adequately lubricated with the specified grease (Fuchs Gleitmo 805).

Ensure electrical cables are correctly positioned and secured to prevent snagging during travel.
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Operationally check the lift for correct function and smooth travel.

Check the function of the emergency drive (Note: if the lift has been isolated for some time the
batteries may need time to recharge).

Upon completion, clean down the lift and dispose of cleaning materials, old components, etc. in
accordance with company procedures.

Fig.8. Remember to fit the Drive Belt PRIOR to assembling the Bottom Plate

Fig.9. Drive complete with Motor and Screw

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 Fig.10. Gap between Safety Nut tube and Top Plate.
Hole through Safety and Drive Nuts for Checking Nut Wear

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